Adapter for mounting a faceplate of a first style to an electrical outlet cavity of a second style

ABSTRACT

An adapter for mounting electrical outlet faceplates designed for mounting on rectangular junction boxes in hollow walls onto solid walls with cylindrical cavities and sleeves. Junction box mounting is popular in North America, whereas cavity mounting is popular in Europe and the Middle East. Such an adapter provides universal mounting for specialized faceplates which are designed and intended for junction box mounting. The adapter features clamps for gripping the inner surface of a wall cavity or sleeve and a rectangular plate for mounting an faceplate designed for junction box mounting. The rectangular plate has mounting points with a nominal center-to-center distance of  3   a  inches, corresponding to the requirements of junction box mounting.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a continuation of copending application Ser. No. 11/006,582,which is itself a continuation of parent application Ser. No.10/451,544, nationalized Jun. 24, 2003, which parent application is thenational stage of international application PCT/IL01/00896, filed Sep.25, 2001, and is now U.S. Pat. No. 6,927,340, issued on Aug. 9, 2005.

FIELD OF THE INVENTION

The present invention relates to a mechanical mounting adapter forelectrical fixtures and the like, and, more particularly, to a wallmounting adapter for outlets and similar fixtures.

BACKGROUND OF THE INVENTION

Wall outlets for electrical apparatus and the like are in widespreaduse, allowing convenient connection of devices such as electricalappliances, telephones, cable television receivers, and computers toelectrical power mains and communication networks. In addition, similarfixtures are often attached to walls, floors, and ceilings, and areconnected in like manner to electrical power and communicationsnetworks. The term “wall” herein denotes any fixed surface to whichsocket outlets are commonly connected and includes, without limitation,walls of a building or similar structure regardless of orientation(including, but not limited to vertical walls, as well as floors andceilings), as well as surfaces of other structures to which socketoutlets may be fixed, such as cupboards and desk tops particularly whenfixedly mounted in a room. Likewise, the term “outlet” herein denotes anon-limiting instance of a fixture for attachment to a wall or otherfixed structure, enabling access to in-wall wiring, commonly viafaceplate panel connector. Other fixture types include, but are notlimited to, wall-mounted electrical lighting and appliances, controls,switches, sensors, data devices, telephony equipment, andintercommunication devices. Outlets commonly uses in-wall dedicatedcavity, but some types are surface-mount, fully installed over the wallsurface.

Outlets commonly comprise two distinct parts:

(a) Faceplate. The outer part of the outlet, commonly formed of plasticand comprising a front panel accommodating a standard connector forconnecting to the in-wall wiring. The front panel of the faceplate isusually decorative, being the only exposed outlet part after theinstallation.

(b) Wall mounting fixture. This fixture is mechanically attached to thewall on the wall inner side, and is attached to the faceplate on thewall outer side thereby fixing the outlet to the wall. Commonly, thefaceplate is attached to the wall-mounting fixture be means of twoscrews.

There are two principal outlet types that are in common use, dependingon the style of wall construction and the opportunities consequentlyavailable for mechanically attaching fixtures to a wall and providingelectrical or signal connections thereto.

One such wall mounting fixture system is the “junction box” style asillustrated in FIG. 1. The junction box style is common in North Americaand is used with a hollow wall construction in which a wall section 101is held in place and supported by a support beam 103, wherein suchsupport beams are placed at suitable intervals. Typically, wall section101 may be a relatively thin panel of gypsum or other material(approximately one-half inch thick), and the support beam 103 is usuallyof wood or metal. A rectangular junction box 105 is securely fastened tothe support beam 103, but may alternatively be affixed to any othersuitable supporting structure. The junction box 105 has an open face107, which is exposed through a matching opening cut into the wallsection 101. Commonly, the junction box 105 is made of metal or plastic,although other suitable materials may be employed. Mounting tabs 109-aand 109-b are provided on opposing sides of the face 107 and accommodatethreaded mounting holes 111-a and 111-b allowing the attachment ofvarious electrical fixtures to the junction box 105. It is to be notedthat the nominal center distance between the mounting holes 111-a and111-b is substantially three and one-quarter (3¼) inches. Media 113enters the junction box 105, optionally via a conduit (not shown), whichconnects to the junction box 105 in one of several optional apertures(not shown) in the closed faces. Media 113 can carry electrical power,telephony signals, or other signals for sensing, data, or control. Anynumber of media 113 can be used, and can include different combinationsand configurations of electrical conductors, such as wires or coaxialcable; or non-conducting media, such as optical fiber.

FIG. 2 illustrates how a faceplate 201 (or similar fixture) is mountedaccording to the junction box system (wall section 101 in FIG. 1 isomitted for clarity). Screws 203-a and 203-b affix faceplate 201 tojunction box 105 through the mounting holes 111-a and 111-b,respectively. Because junction box 105 is secured to the support beam103 (or other suitable supporting structure), the faceplate 201 isthereby securely fastened in place. Faceplate 201 comprises twotelephony connectors (such as RJ-11), connected to in-walltelephone-wiring, hence being part of telephone outlet. As can be seenin FIG. 2, the faceplate 201 is designed to be coupled to the wallmounting fixture 105, by means of mechanical size and rectangular shape,intended to cover all fixture 105 cavity, and holes matched for screws203 to fit threads 111.

The second commonly used wall mounting method is the “cylindrical cavityand sleeve” style as illustrated in FIG. 3. The cylindrical cavity andsleeve style is common in Europe and the Middle East and is used with aconstruction in which a wall section 301 is made of solid, orsubstantially solid masonry or similar rigid material which isself-supporting and requires no additional structural elements forstability. A cylindrical cavity 303 is formed in the wall section 301,and an optional sleeve 305 is inserted therein from the outside. Thesleeve 305 is commonly of plastic or other semi-flexible material, andtypically is in the shape of a cup with a lip and closed back. Thesleeve 305 may also have mounting screws (not shown) for affixing to thewall section 301.

FIG. 4 shows a prior art wall mounting fixture device 401 for thecylindrical cavity and sleeve style of wall mounting. A pair ofexpandable clamps 403-a and 403-b is positioned to grip the inside ofthe sleeve 305 (FIG. 3), or alternatively the inside of the cavity 303if no sleeve 305 is present. Cavities are typically cylindrical with aninside diameter of approximately 5.5 centimeters, but other cavityshapes and sizes are in general also possible. Clamp 403-a can beexpanded outward to engage a grip on the inside of sleeve 305 (andsubsequently increase the grip strength) by tightening a screw 405, andclamp 403-b can likewise be expanded outward for this purpose by asimilar screw (not shown). It is also possible to use a singleexpandable clamp in conjunction with a fixed clamp or similar projectionthat is capable of gripping the inner surface of sleeve 305 or theinside of cavity 303 if no sleeve 305 is present. Once the wall mountingsure device 401 has been secured inside the cavity 303, the faceplate(not shown) may be fastened to attachment device 401 by means of screwsdriven into mounting holes 407-a and 407-b. It is to be noted that thenominal center distance between mounting holes 407-a and 407-b is six(6.0) centimeters, which is approximately 2.36 inches. The faceplate isalso well suited to the wall mounting fixture, being of square shape,and having screw holes suitable for affixing the faceplate into the wallmounting fixture.

It is further noted that:

the prior art wall mounting fixture device as illustrated in FIG. 4 anddescribed herein is capable of mounting substantially all commonly-usedfixtures and outlets intended for cylindrical cavity and sleeve wallmounting;

all variations in the design and configuration of such prior art wallmounting fixture devices are minor, so that all such prior art wallmounting fixture devices are substantially identical in appearance, use,and function;

wall mounting fixtures and faceplates designed for the junction boxstyle of wall mounting are incompatible with, and cannot be mounted in,cylindrical cavity and sleeve construction using the available priorfixture attachment devices (as illustrated in FIG. 4 and as describedherein); and

no means of readily mounting fixtures and outlets designed for thejunction box style of wall mounting is currently available forcylindrical cavity and sleeve construction.

All common fixture and outlet types (such as electrical power outlets,telephone jacks, and lighting fixtures) are widely available for both ofthe above wall mounting styles. Thus, regardless of which style of wallmounting is employed within a building, it is easy to obtain thesecommon fixtures and outlet types for that wall mounting style.

Many specialized fixtures and outlets, however, are now becomingavailable for specific purposes. Non-limiting examples of suchspecialized fixtures and outlets include outlets for data networking,multi-media, sensors, control units, and the like. Such fixtures andoutlets may not be readily available for both wall mounting styles. Ingeneral, such specialized wall mounting fixtures and faceplates tend tobe available for the wall mounting style that is prevalent in the regionwhere their most important market is located. In particular, because ofthe size and importance of the North American market, most suchspecialized wall mounting fixtures and faceplates tend to be availableprimarily for the junction box style of wall mounting, as illustrated inFIG. 1 and FIG. 2. In many cases, such specialized wall mountingfixtures and faceplates are not available for the cylindrical cavity andsleeve style. Where this is the case, specialized wall mounting fixturesand faceplates cannot easily be installed in buildings whoseconstruction utilizes the cylindrical cavity and sleeve style of wallmounting without expensive and unsightly external retrofitting ofjunction boxes 105 within the smaller cavities 303 provided for thesleeves 305, and therefore the utility provided by such specialized wallmounting fixtures and faceplates is difficult and expensive to providefor those buildings.

There is thus a widely recognized need for, and it would be highlyadvantageous to have, an adapter which provides easy installation offaceplates designed for the junction box style of wall mounting inbuildings whose construction utilizes the cylindrical cavity and sleevestyle of wall mounting. More generally, there is a need for an adapterallowing a faceplate of one style to be installed in a cavity suitablefor another distinct style. This goal is met by the present invention.

SUMMARY OF THE INVENTION

The present invention provides an adapter that permits mounting afixture or outlet designed for the junction box style of wall mountingto be installed in a cylindrical or other shaped cavity, with or withouta sleeve.

The adapter according to the present invention readily installs into awall cavity with or without a sleeve, and accepts the attachment of afixture or outlet designed for the junction box style of wall mounting.

Therefore, according to the present invention there is provided anadapter for mounting a faceplate of a first style on to an outlet cavityof a second style, the adapter comprising:

a plate having an opening for passing therethrough media for connectingto at least one connector mounted in said faceplate,

at least one fastener fixed to the plate for fixedly attaching theadapter to the outlet cavity; and

at least one mounting point for attaching the faceplate thereto.

Preferably, a pair of spaced apart mounting points are provided in theplate separated by a distance of substantially 3¼ inches, conforming tothe mutual separation between corresponding mounting holes ofcommercially available junction box faceplates.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the invention and to see how it may be carriedout in practice, a preferred embodiment will now be described, by way ofnon-limiting example only, with reference to the accompanying drawings,in which:

FIG. 1 illustrates the prior art junction box style of wall mountingfixture.

FIG. 2 illustrates the prior art installation of a faceplate onto ajunction box style wall mounting fixture.

FIG. 3 illustrates the prior art cylindrical cavity and sleeve style ofwall mounting cavity.

FIG. 4 illustrates a prior art wall mounting fixture device for thecylindrical cavity and sleeve style.

FIG. 5 illustrates an adapter according to the present invention forinstalling a faceplate designed for the junction box style to a wallmounting fixture in a cylindrical cavity.

FIG. 6 illustrates the installation of a outlet faceplate onto anadapter according to the present invention into a cylindrical cavitysleeve.

FIG. 7 illustrates an embodiment of the present invention having boxedsides and mounting posts.

DETAILED DESCRIPTION OF THE INVENTION

The principles and operation of an adapter according to the presentinvention may be understood with reference to the drawings and theaccompanying description, wherein components that are common todifferent embodiments are referenced by identical reference numerals.

FIG. 5 illustrates an adapter 501 having a rectangular plate 503 with anopening 505 for passing media 113 (FIG. 3) therethrough and havingexpandable clamps 403-a and 403-b for gripping to the interior surfaceof a wall cavity or sleeve. A screw 405 expands clamp 403-a, and asimilar screw (not shown) expands clamp 403-b. Mounting points 507-a and507-b permit attachment of a faceplate designed for the junction boxstyle of wall mounting. Accordingly, the nominal center distance betweenmounting points 507-a and 507-b is substantially three and one-quarter(3¼) inches. Non-limiting examples of mounting points 507-a and 507-binclude holes and posts, which may be threaded as well as friction orsnap-fit.

FIG. 6 illustrates the mounting of an faceplate 601 designed forjunction box style mounting on to adapter 501, which inserts into sleeve305 and attaches therein with clamps 403-a and 403-b when the respectivescrews 405 are tightened (for clarity, wall section 301 is not shown).Having thus been securely fastened, the adapter 501 is then ready forthe mounting of faceplate 601 against the rectangular plate 503.Faceplate 601 has mounting holes 603-a and 603-b, into which screws605-a and 605-b, respectively, are passed and affixed into mountingpoints 507-a and 507-b, respectively, which may for example be threadedscrew holes. Prior to mounting, media 113 is passed through opening 505for connection to an appropriate device (not shown) fixed within thefaceplate 601.

In the manner illustrated in FIG. 6 and described above, a customizedfaceplate designed for junction box mounting can be flush mounted neatlyand easily on a wall featuring the cavity and sleeve style of wallmounting.

Faceplate 601 as illustrated in FIG. 6 has a raised body intended forsurface mounting on a wall such that the plate 503 mounts flush againstthe wall. An alternative embodiment of the present invention, however,is for mounting faceplates and other fixtures intended for mountinginside a junction box. FIG. 7 illustrates such an adapter wherein theplate 503 shown in FIG. 6 serves as a back plate supporting around aperimeter thereof a generally boxlike construction comprising outersides 703 forming a junction box, and accommodating therein mountingpoints 705-a and 705-b in the form of raised posts. The raised postshave a threaded bore for threadably attaching the faceplate 601 thereto.The outer sides 703 are positioned so that when mounted, the adaptergives an appearance of a junction box flush to the wall. Outer sides 703can be made with a variety of heights, so that a shallow and moreattractive junction box is possible.

While the invention has been so far described with respect to arectangular, junction-box style faceplate mounted into circular wallcavity, it will be appreciated that the invention can be equally appliedto any case wherein a faceplate of one style is required to be mountedon to an outlet cavity conforming to a different style.

Likewise, while the invention has been described with respect to alimited number of embodiments, it will be appreciated that manyvariations, modifications, and other applications of the invention maybe made. All such embodiments are contemplated as fall within the scopeof the appended claims.

Thus, for example, although a pair of spaced apart clamps is shown inFIGS. 6 and 7 for fixing the adapter to the outlet cavity or sleeve, itwill be appreciated that other means of attachment are possible. Forexample, an aperture may be formed in the plate 503 at a location thatfalls within the circumferences of the cavity 303 or the sleeve 305,thus allowing the plate to be screwed to the wall 101 through the cavity303: or the sleeve 305. Likewise, in FIG. 7, the clamps areinterconnected by an armature shown as 707 and having a central aperture709, thus again allowing the plate to be screwed to the wall 101 throughthe cavity 303 or the sleeve 305 and obviating the need for the clamps.

The faceplate 601 shown in FIG. 6 includes a pair of apertures 606-a and606-b each for accommodating a respective connector. Such connector caninclude a telephone connector, 609-a, 609-b, as shown in FIG. 6, apower/electricity connector or a CATV connector. In the case that thefaceplate 601 accommodates multiple apertures (which is not mandatory),the apertures may, if desired, by of different contours so as to allowdifferent types of connector to be mounted therein. By such means, forexample, a telephone connector and a computer data connector can beaccommodated in the same connector and connected to appropriate media,the faceplate 601 being fixed to the cavity 303 or to the sleeve 305 viathe adapter 501 or 701.

The invention also contemplates a method for installing a faceplate of afirst style into an electrical outlet cavity of a second style, themethod comprising:

(a) mounting to the outlet cavity an adapter according to the invention,

(b) connecting the media to at least one connector mounted in thefaceplate of the adapter, and

(c) fixing the faceplate to the adapter via the at least one mountingpoint.

Likewise, the invention contemplates an electrical outlet comprising afaceplate of a fist style mounted on to an outlet cavity of a secondstyle via an adapter according to the invention.

1. An adapter to mount a faceplate having a rectangular shape to anelectrical outlet cavity having a circular shape, the faceplate carryingat least one connector, the adapter comprising: a plate having anopening for passage therethrough of media for connecting to the at leastone connector mounted in the faceplate having a rectangular shape, saidplate having at least one mounting element located and configured toattach the faceplate to said plate; and at least one fastener fixed tosaid plate and configured to fixedly attach said adapter to theelectrical outlet cavity.
 2. The adapter according to claim 1, whereinthe at least one fastener comprises a pair of spaced apart clamps forengaging an inner surface of the outlet cavity.
 3. The adapter accordingto claim 1, wherein the at least one fastener comprises a pair of spacedapart clamps for engaging an inner surface of a sleeve fixed in theoutlet cavity.
 4. The adapter according to claim 1, wherein said atleast one mounting element comprises a pair of spaced apart mountingpoints for attaching the faceplate to said plate.
 5. The adapteraccording to claim 4, wherein the pair of mounting points are mutuallyseparated by a distance of 3¼ inches.
 6. The adapter of claim 1, whereinthe at least one mounting element consists of one of: holes, posts,threaded holes, threaded posts, friction-fit posts and snap-fit posts.7. The adapter of claim 1, wherein said plate serves as a back platehaving a perimeter supporting a generally boxlike constructioncomprising outer sides, thereby forming a junction box.
 8. The adapteraccording to claim 7, wherein the at least one mounting elementcomprises a pair of raised posts.
 9. An electrical outlet comprising:said faceplate having said rectangular shape; and said adapter accordingto claim 1 to which said faceplate is attachable and which is attachableto the electrical outlet cavity having the second configuration.
 10. Theelectrical outlet according to claim 9, wherein the at least oneconnector includes a telephone connector.
 11. The electrical outletaccording to claim 9, wherein the at least one connector includes apower/electricity connector.
 12. The electrical outlet according toclaim 9, wherein the at least one connector includes a cable televisionconnector.
 13. The electrical outlet according to claim 9, wherein theat least one connector includes a computer data connector.
 14. A methodfor installing a faceplate having a rectangular shape to an electricaloutlet cavity having a circular shape, the faceplate carrying at leastone connector, the method comprising: (a) mounting to the outlet cavitysaid adapter according to claim 1; (b) connecting the media to the atleast one connector carried by the faceplate; and (c) fixing thefaceplate to the adapter via the at least one mounting element.